Robot Arm Force Feedback for Workcell Boundary Mapping
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Solution Overview
Problem
Industrial robotic systems face challenges in accurately representing the physical operating environment, leading to inaccuracies in robotic motion and potential collisions, due to limitations in camera-based measurements that may not provide complete information, especially for inaccessible areas.
Innovation Solution
A computer-implemented method that uses a robot arm with sensors to record force measurements at object boundaries, generating a spatial map of the environment and updating the virtual representation to accurately depict physical boundaries, thereby improving the accuracy of the simulation and ensuring parity between the physical and virtual environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If camera-based measurements are used to represent the physical environment, then the system complexity is reduced, but the measurement precision and completeness of environmental data deteriorate due to inaccessible viewpoints
Solution Approach 1:
A force sensor is introduced as an intermediary between the robot arm and the environment to indirectly detect physical boundaries. The force sensor measures contact forces when the robot arm interacts with objects, providing measurement data from viewpoints that cameras cannot access, thus improving environmental representation completeness without significantly increasing system complexity
Solution Approach 2:
The patent replaces optical measurement (camera-based) with mechanical measurement (force sensor-based). Instead of using light to detect environment, the system uses mechanical contact and force measurement to gather environmental data, enabling detection in areas inaccessible to cameras while maintaining relatively simple system architecture
2Manufacturing precision
If the virtual representation is updated with force feedback data, then the manufacturing precision of robotic operations is improved, but the loss of time for calibration and data collection increases
Solution Approach 1:
The system performs preliminary calibration by having the robot arm systematically explore the environment and collect force feedback data before actual manufacturing operations. This preliminary action creates an accurate virtual representation that can be reused for multiple operations, reducing calibration time for subsequent tasks
Solution Approach 2:
The force feedback data collection is integrated into the robot's normal operation workflow. Instead of separate calibration phases, the system continuously gathers environmental data during robot movement and operation, transforming calibration from a discrete time-consuming task into a continuous process that occurs during useful robotic actions
3Measurement precision
If force sensors are used to detect physical boundaries, then the measurement precision of object locations is improved, but the device complexity increases due to additional sensing requirements
Solution Approach 1:
The force sensor serves multiple functions: it detects object boundaries, measures contact forces, validates virtual environment accuracy, and provides feedback for motion planning. This multi-functionality justifies the added device complexity by providing comprehensive environmental awareness from a single sensor type
Solution Approach 2:
The force sensor is integrated with the robot arm's end effector, merging the sensing function with the actuation system. This integration reduces overall system complexity compared to having separate sensing and actuation systems, as the force sensor becomes an inherent part of the robot's interaction interface with the environment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the precision and safety of robotic operations by providing an accurate representation of the physical environment, allowing for better motion planning and collision avoidance, and improving the overall performance of robotic systems in manufacturing processes.
Implementation Method 1
measures the reaction force with a force sensor provided at the tip of the arm
Data Source
AI summary
In one aspect, there is provided a computer-implemented method that includes receiving a request to generate workcell data representing physical dimensions of a workcell having a physical robot arm, executing a calibration program that causes the physical robot arm to move within the workcell and record locations within the workcell at which the robot arm made contact with an object, generating, from the locations within the workcell at which one or more sensors of the robot arm recorded a resistance above a threshold, a representation of physical boundaries in the workcell, obtaining an initial virtual representation of the workcell, and updating the initial virtual representation of the workcell according to the representation of physical boundaries generated from executing the calibration program.